Automatic control system for correcting textile machinery malfunctions from sensed and stored malfunction data

ABSTRACT

A spinning frame having a plurality of spindles with bobbins thereon being wound simultaneously with yarn has a travelling service tender that monitors each spindle work station over a trip through all spindle positions to determine and correct malfunctions performed by an automatic service cycle performed at each spindle location work station requiring attention. Thus, full bobbins are detected and doffed, roll wraps are detected and stations disabled, flag down spindles are bypassed, and improper yarn feed is sensed and corrected by the service tender for each station encountered on a trip requiring such service. Stored data is retained to indicate the position and type of malfunctions and various indications of the machine performance and efficiency. Counters store data individually for each spindle and accumulate data for all spindles traversed. Provision is made to control the machine operation from either the detected or stored data by modifying the service cycles, the service trips, or shutting down operations if the danger of machine damage occurs. Alarms or other controls are operated from the stored data if the machine efficiency indicates the need for service outside the automatic tender operation, and the data is retained for indication of machine performance, efficiency and for trouble shooting analysis.

Unite States Patent [191 Bernstein et a1.

[ 51 Feb 5, 1974 [75] Inventors: Barry E. Bernstein, Warwick; Robert S. Erbstein, Coventry; Thomas Pazis, North Kingstown, all

of RI.

[73] Assignee: Leesona Corporation, Warwick, RI.

[22] Filed: Dec. 20, 1971 211 App]. No.: 209,774

[52] US. Cl 57/34 R, 57/54, 57/156 [51] Int. Cl D0lh 13/32 [58] Field 01 Search 57/52-54, 78-87,

[56] References Cited UNITED STATES PATENTS 3,403,866 10/1968 Bell et al 57/53 X 3,638,412 2/1972 Rebsamen 57/52 3,660,972 5/1972 Neill et al. 57/34 R 3,672,143 6/1972 Whitney 57/53 3,680,297 8/1972 Lee, Jr. 57/34 R 3,680,298 8/1972 Saunders 57/34 R 3,680,299 8/1972 Lee, Jr. 57/34 R '7 '7 Norton [5 7] ABSTRACT A spinning frame having a plurality of spindles with bobbins thereon being wound simultaneously with yarn has a travelling service tender that monitors each spindle work station over a trip through all spindle positions to determine and correct malfunctions performed by an automatic service cycle performed at each spindle location work station requiring attention. Thus, full bobbins are detected and doffed, roll wraps are detected and stations disabled, flag down spindles are bypassed, and improper yarn feed is sensed and corrected by the service tender for each station encountered on a trip requiring such service.

Stored data is retained to indicate the position and type of malfunctions and various indications of the machine performance and efficiency. Counters store data individually for each spindle and accumulate data for all spindles traversed. Provision is made to control the machine operation from either the detected or stored data by modifying .the service cycles, the service trips, or shutting down operations if the danger of machine damage occurs. Alarms or other controls are operated from the stored data if the machine efficiency indicates the need for service outside the automatic tender operation, and the data is retained for indication of machine performance, efficiency and for trouble shooting analysis.

40 Claims, 7 Drawing Figures TRAVELLING SERVICE TENDER SPINNING FRAME Pmmzum 51914 3.789.595

sum 1 of I TRAVELLING/ I SERVICE TENDER FRAME FIG.5

INVENTORS BARRY E. BERNSTEIN ROBERT s. ERBSTEIN BY THOMAS PAZIS ATTORNEYS AUTOMATIC CONTROL SYSTEM FOR CORRECTING TEXTllLE MACHINERY MALFUNCTIONS FROM SENSE!) AND STORED MALFUNCTION DATA INTRODUCTION This invention relates to winding machinery and more particularly it relates to textile spinning frames and data processing systems therefor which sense and display information regarding failures and machine efficiency.

Multiple spindle spinning frames are well known in the art and the details will only be described hereinafter to the extent necessary to provide an understanding of the present invention. Thus the state of the art is represented by U. S. Pat. No. 3,403,866 to C. C. Bell et al, Oct. 1, 1968, which is included by reference as part of this disclosure. The Patent fully describes the mechanical structure and layout of a multiple spindle spinning frame having a traversing service tender automatically servicing work stations spindle by spindle to doff and don bobbins. Sequencing and programming controls for such apparatus are disclosed in U. S. Pat. No. 3,539,878 to C. C. Bell et al, Nov. 10, 1970, also included herein by reference.

In the operation of the foregoing and equivalent automatic equipment certain conditions may result that will'demage the machine if it is not shut down. Other malfunctions may be present or may accumulate to such extent indicating the efficiency of the machine is low enough that repairs should be made to increase the output. In addition it is desirable to expand the capabilities of such machines to provide production and management information based upon current and cumulative or historical data derived from operations at the various work stations.

Some of the specific operations, problems and ma]- functions in the spinning frame embodiment of the invention that may result in machine damage or poor efficiency, or that may provide essential management production data are outlined generally in the following portions of the description.

In the spinning frames of the type aforesaid, provisions are made to keep bobbins winding for as many spindles as are properly operational but to disable individually those spindle stations which are in need of repair. Thus a shunt mechanism is provided for disabling the individual stations by moving a lever or flag. Such disabled stations are identified by the terminology flag down.

One malfunction for which stations generally are disabled until repairs are manually made by a service man is known as roll wrap. This happens when the strand feed becomes caught in feed rollers and wraps around the roller to build up an entanglement of the strand.

The breaking of a strand or other improper feed could result in roll wrap, and it likewise indicates that a bobbin is not being would properly, or that the strand is cut.

A full bobbin is termed herein a malfunction, since it requires servicing by doffing the bobbin before it becomes too full. When a bobbin is overfilled it rubs on the equipment and is termed a black bobbin which is not usable. Accordingly it is more important to doff productive full bobbins than to service or load inoperative stations or those at which partially filled bobbin are present.

Certain conditions and combinations of conditions can indicate danger of damage to the spinning frame, or trouble requiring service at a station, in the spinning frame or in the service tender. Representative of these combinations are the following examples. If a successive number of stations cannot be successfully serviced, then possibly the spinning frame is out of alignment or is malfunctioning to such an extent it should be shut down. A combination where the number of improper strand feeds is low and the number of service cycles is high shows a malfunction of the service tender where either the data is erroneously sensed or the machine is not properly servicing the required stations. The machine may be doffing bobbins unnecessarily and an alarm condition may be desired. If the service tender has a recycling repeat service cycle provision, a large number of second recycling tries may be an indication of improper machine performance that requires service even if the second tries are successful. Also a low count of operable spindles or a high count of roll wraps can give indications of trouble. Some of these conditions show inefficiency of operations, which permits the machine to operate pending repair with an alarm light or the like indicating the need for repair. Others signal the need to shut down to avoid the possibility of damage if the automatic cycling continues. Also some signals may indicate-whether an attendant serviceman is able to keep the machine operating satisfactorily.

In the operation of this type of machine in an automatic mode, three cycle times are critical. A servicing cycle should be completed within a known period, for

example, 20 seconds. If it does exceed such a specified time, it is an indication the mechanism has become jammed or otherwise the operation is so abnormal that the machine should be stopped for repair. Likewise a complete service tender trip about all stations should be made in a sepeified time of perhaps three minutes. If not then this indicates a similar trouble condition. Also, a full bobbin should be detected within a specifled time. This indicates proper functioning of the full bobbin detector, the spinning operation, and an essentially uniform pattern of full bobbins.

For the purpose of maintenance on the spinning frame it is desirable to know the history of each spindle and the nature of any malfunctions. If any one spindle chronically encounters improper strand feed or roll wrap conditions it may need repair, even though the operation can continue on a less efficient basis temporarily. Similarly, in maintenance of the service tender, certain historical data may point to trouble areas. For example if a service operation stop were made at a station having a flag down, the tender is operating abnormally. If data regarding other such conditions is available, operation and maintenance conditions may be monitored, analyzed and expedited.

Production figures and management planning information is also desirable for production equipment of the type described. It is important therefore to know machine efficiency, the production output and the record of the serviceman attending the machine in keeping it operable at highest efficiency. Thus certain data such as the number of full and partial bobbins doffed, the number of stations in service, etc. becomes important.

Output data from various malfunction indicators need be displayed in different forms for different purposes. Sometimes a current visual count readout is sufficient. Other conditions may require a recorded output or an alarm to be lighted or sounded at a predetermined count or combination of conditions. In addition to automate and operate more comprehensive systems, the availability of electronic output signals that can operate solenoids, relays or logic circuits is important. Some data processing functions are also important such as the determination of the rate of malfunctions per machine cycle or per time period.

Thus it is a general object of the present invention to provide improved winding equipment incorporating the foregoing features and resolving the foregoing problems.

It is another object of the invention to provide automatic textile machinery providing data production outputs for indicating production efficiency.

Still another object of the invention is to provide service controls for automatic textile machinery to indicate malfunctions and to prevent machine damage when selected malfunction conditions are encountered.

An object of the invention is to provide a data processing system operable in combination with automatic textile machinery.

A more specific object of the invention is to provide automated controls for automatically processing yarn in a multiple spindle spinning frame, servicing the equipment upon encountering malfunctions, and producing current and historical operational data for indicating machine performance.

Other features, advantages and objectives of this invention will be found throughout the following description of a specific embodiment of the invention with reference to the accompanying drawing, wherein:

FIG. 1 is a logical sketch of a textile machine and its mode of operation,

FIG. 2 (two sheets) is a block diagram of the control and data processing system operable with textile machinery such as that of FIG. 1 embodying the invention and showing both its construction and mode of operation, and

FIGS. 3 to 7 are sketches of malfunction condition sensors that may be used in textile equipment of the type embodying the present invention.

In order to avoid obscuring the nature and scope of the present invention, the description is made with a minimal reference to the conventional complex machinery involved in the afore-mentioned patents, and is presented in block diagram form without complex electronic circuit construction details where the equipment is conventional. The block diagrams are of the one line type, it being clear that those skilled in the art of electronic data processing equipment conventionally assemble systems from standard off-the-shelf building modules such as amplifiers, counters and logic gates providing the necessary ground and power connections with interconnected timing pulses and sequencing to make the system operable in the ordinary course of their work.

GENERAL BACKGROUND STATUS A multiple spindle spinning frame of the type described in the aforementioned patent is-depicted in FIG. 1. Thus a spinning frame 11 has a travelling service tender l2 directed about a track 13 in the direction of arrow 10 from start 17 to end 16 to service bobbins 14 at a plurality N of stations located by spindles 15 when they are detected by tender 12. The tender is centered and stopped for service when required at an exact location designated by arrow 18. The track length, configuration and number of spindles may vary and a tender can pass from module to module through several spinning frames.

The tender can be started by an automatic or manual signal to move from a location 17 to traverse a given path defined by track 13 to end at location 16. Appropriate switches may provide start and end of cycle signal or control pulses at locations 16 and 17. During the trip cycle the spindles l, 2 N are traversed in a known sequence so that each spindle may be identified as the trip progresses.

The tender has equipment either contained therein or operable therewith for detecting malfunction signals (hereinafter described) and accordingly for operating it in one of several mechanical modes described in detail in the referenced patents. Thus, the service tender will doff bobbins and cut the strand being wound and will don new bobbins and connect the strand for winding. Also it will operate a disabling shunt and put a flag down if a service cycle cannot be completed, and will cycle automatically through a programmed service step sequence cycle which can be repeated if a first service try fails.

GENERAL MACHINE CONTROL AND DATA PROCESSING OPERATION As shown in FIG. 2, the travelling service tender 12 incorporates in its control system a data processing and machine control section divided into two sections primarily serving respectively data collection and service functions. The control equipment in general may comprise electronic circuitry which operates for all practical purposes instantaneously with respect to mechanical operations in the machines, although in some cases equivalent mechanical or electromechanical operations may be desirable. The electronic system permits control signals to be generated for electromechanically operable equipment such as driving relays, motors, electromagnetic brakes or solenoids. Also alarms or light may be actuated and counters or counter displays may be used for either mechanical, electromechanical, pneumatic, or electronic type as the functioning or location may require. Thus an operating mechanism may close a switch to count on a standard conventional electromagnetic accumulating counter which will print out a record strip at any time desired, for example. Alternatively the counter may comprise an electronic counter which dynamically retains cumulated counts for interrogation by electronic pulses at any desired time for use in the system or alternatively to go to a central display or control center. The counters may be preset to read out at any preset count in a conventional manner.

In the data section, inputs are obtained from a set of detectors for providing signals from the various following conditions: (1) When the center of the spindle is reached a pulsed signal G is produced by spindle detector 40 which permits the tender to stop its travel at that exact position if another signal is sensed making a service stop desirable. This signal G is used as a gating and control pulse elsewhere in the system. (2) A flag down sensor 50 provides a signal D at each station when it is in service, which signal persists as long as the tender is stopped at the station and thus comprises a steady state condition. (3) The roll wrap detector 60 senses at the station being serviced a roll wrap at any time it starts building and makes available a steady state signal R. (4) The strand feed detector 70 senses the strand at a point in the bobbin winding network of the spindle station being serviced that indicates the strand is properly feeding and winding. (5) If a bobbin is full, detector 45 gives a steady state signal F of that condition for the spindle station at which the tender 12 stops. (6) A roving detector senses at the station being serviced the presence of properly positioned roving.

Thus, the various input signals are sensed and processed for various storage, counting and machine control modes of operation hereinafter discussed.

In the service section, the service cycle programmer operates the servicing cycle through one or more of several modes while the tender 12 is stopped on a spindle. The cycle is started as shown at 21 to go through its bobbin doffing mode 22, its donning a new bobbin mode 23, and the flag down mode 24 which takes a spindle station out of service and puts the flag down. When a service operation is completed the tender is started on its patrol to the next station requiring service. However if the service cycle is not successful and a malfunction is detected at time T of block 25, the program permits a service cycle mode to repeat the service cycle at control section 26.

In this service section, the machine is controlled in several respects, such as by operating the tender drive means 27, stopping the spinning frame (28) or simply providing a visual alarm (29) indicating the need for non-emergency repairs.

Further data is counted and recorded in the service section as the various service operations are in process. The outputs of the data section comprise various counts of malfunctions. The counts may be accumulated for allmalfunctions encountered over a designated time or number of service cycles or trips or alternatively may be accumulated for each individual spindle. The counts may be logged from visual counter readouts and processed manually or they may be automatically periodically read out and displayed or recorded on strip charts or individual counter types as generally indicated at block 30.

The outputs of the service section include historical data records and counts, but in addition comprise control signals for driving and stopping the tender 27 and the spinning frame 28 or for establishing any visual or recorded alarm signals or operation of relays used for automatic service operations, etc. (29).

DATA COLLECTION In the disclosed embodiment data is stored primarily by counting malfunctions and other operational conditions either directly from raw detected signals or indi rectly from signals conditioned or processed alone or together with other signals and presented in modified form. It is to be recognized that certain preferred signals are disclosed with particularity as representative of the general manner of processing various malfunction signals and combinations thereof and applicable to a special type of textile machinery. The embodiment by way of example rather than restriction includes a representative combination of signals for storing data to achieve the three purposes of (1) preventing damage to the machine, (2) providing production data to management for evaluation and planning, and (3) providing data that can be used to increase the efficiency of operation. Some or all of these data may be afforded or required in different installations, and other data may be used supplementally with these data.

As seen from FIGS. 1 and 2, as the service tender traverses its track and passes from spindle to spindle a gating pulse G is derived from each spindle at lead 42. As a basis for measuring operational efficiency of the entire system, a total spindle count may be required and is provided by a spindle counter 41. This count may be taken together with the number of spindles inoperable and those requiring service (hereinafter described) to provide efficiency ratios.

In each tender trip,- N spindles will be scanned, and each current spindle position is identified by the spindle commutator 43. This could be a stepping switch or electronic equivalent which is advanced one position by each spindle gating pulse G and which is synchronized by trip start or END pulses obtained at positions 16 and 17 in FIG. l. .The current tender position may be remotely displayed from the commutator 43 in a control center panel, if desired so that the operable status of the system can be continuously or periodically monitored. Thus the commutator may have lighted position indicators, and it provides position gating signals on leads 1, 2, 3 N that may be used for directing counts into each bank 31 to 37 of a matrix of separate spindle data counters.

Accordingly in representative counter bank 31, the flag down signal derived at lead 52, and gated with the spindle pulse G at AND circuit 53 will provide a count on lead 54 for registering a total accumulative flags down count in counter 51 and a flag down per spindle count in each individual spindle counter Section 31A, 31B, etc. of counter bank 31, as gated and distributed by the action of spindle commutator 43.

Similarly the other malfunctions such as roll wrap, absence of roving, strand feed and full bobbin are registered in the corresponding cumulative and per-spindle counters, 51, 51', 61, 71, 46 and 31 to 37. All these stored data will permit analysis of machine efficiency and give repair data and some gauge of the repairman s efficiency.

Thus, if a particular spindle tends to accumulate an abnormal number of roll wraps, it will point to the need for repairs or maintenance at that station, etc. The cumulative totals might indicate that the serviceman was not able to repair promptly all the malfunctions so that the machine was not operating efficiently.

When the counters are simple counters with visual display of the registered counts, periodic reading may be taken and logged each hour (or other time period) and the malfunctions per hour figure can be figured. If the cumulative totals are not important the counters can be reset each hour and the reading will represent an error rate. Similarly readings may be taken for each tender service trip or for a specified number of service trips. Conventional solenoid operated electromagnetic counters may be used, for example, which will print out on a strip upon demand. Thus, the system can be further automated to process data by supplying a periodic signal 81 from clock to readout and reset (if desired) counters in either the data or service sections as designated by leads 83 from block 84. Likewise the signal at lead 86 could designate a readout for each service trip or a predetermined count of ten or a hundred trips can be taken from counter 85 for example as indicated at block 84.

Further data is acquired, counted and stored in the service section as discussed hereinafter.

DERIVING INPUT INFORMATION The various input signals are derived by appropriate detectors which may take the form shown in FIGS. 3 to 7 for example. Depending upon system speeds and tolerances and the nature of the signals being detected, the detectors may be position sensitive switches such as Micro-switches or electromagnetically operated reed switches, or they may be electronic detectors such as the photo-electric devices illustrated.

Thus in FIG. 4, a photo-electric spindle detector 40 is shown with lamp 43 and lens 46 focusing a beam of light on the position 49 at which the domed tip of spindle 15 will be presented to thereby reflect through lens 47 or an equivalent slit a signal on photo-detector 48. This or equivalent devices may be used for accurately locating the exact center of spindle 15 at which the gating signals G are provided even when the tender is patrolling without stops.

Also depicted is a full bobbin detector which might take the form of a lamp 55 providing a light beam 59 from lens 56 which is read by photo-detector 58 through lens 57. If the bobbin winding 14 is full as shown by phantom lines 14A, the beam 59 will be interrupted to produce a signal identifying a full bobbin.

If the flag down is indicated by a position of flag lever 62 in FIG. shown in phantom as 62A, then lamp 63 will form a beam 64 through lens 65 which will be reflected through lens 66 to photo-detector 67 and produce a flag down signal as the tender arrives and stops in position at each station, to thereby align the beam 64 with the flag position 62A.

As seen in FIG. 6, if a roll wrap entanglement 68 builds up away from roller 73 from strand 69 as caused by action of rollers 72 and 73 upon the strand, then beam 74 from lamp 75 to photo-detector 76, which otherwise skims roller 73, is reflected to give a roll wrap signal. This beam 74 may be directed axially along roller 73 if desired. Similarly strand feed may be detected by presence of strand 69 in a beam 79 placed to show the yarn, for example, was feeding properly through a mechanism 78, which could be spinning equipment, to pass from the supply 77 properly onto the bobbin 14 at spindle (see FIG. 3).

Roving detector 44 measures the width of the roving package by viewing the light reflected off the roving 69 as seen in FIG. 7. If the supply 77 is empty the beam will not be reflected back to the detector 44 by the roving. This indicates the non-existance of roving. If desired, an empty roving signal can be stored as data, used to alter the tender cycle by, for example, disabling the particular station by knocking-down the signal flag, and indicating to the operator that roving servicing is required.

Thus, the provision of appropriate input signals for detecting the various malfunctions may be produced by location of detection equipment in the tender or on spinning frame to monitor the desired physical movements encountered.

GENERAL MACHINE CONTROL OPERATIONS As shown in FIGS. 1 and 2, the machine control outputs comprise signals (1) to start and stop the tender 12 in the brake-drive unit 27, (2) signals to stop the spinning frame 11 in control block 28, and (3) any appropriate alarm or control signals that may be desired, as represented by block 29.

If the controls are set for trip-by-trip control over the tender, then the END signal can set flip-flop 91 to complete a trip and a start signal will actuate switch 92 to reset the flip-flop 91 and start the tender on a further trip. The number of trips may be counted on counter from trip pulse signals T derived as the flip-flop 91 is reset. This start pulse T then operates a solenoid in the tender drive unit 27 to cause the tender to traverse until it reaches a station signalling for a service stop or the end of the trip as provided by OR gate 94, which serves to operate a stop solenoid controlling an electromagnetic brake (not shown) in the tender brake and drive unit 27.

The tender is stopped for service at any spindle station providing a full bobbin signal F, a roll wrap signal R or an improper strand feed signal S as indicated at OR circuit 95. Then this need for service signal is gated by the spindle position gating signal G at AND gate 96, provided inhibit signals are not present. When the tender is stopped by a stop signal pulse 97 at lead 98, a cycle timer clock 99 is started. If the cycle is not completed in a predetermined time by a reset pulse on lead 100, the spinning frame may be stopped by an end of period signal to OR gate 101. The trip timer 102 operates similarly from start and END signals 16, 17 derived from the tender trip (FIG. 1).

Also, when the tender is stopped, stop signal 97 starts the service cycle program at block 21.

THE BOBBIN CHANGING MODE When either a full bobbin signal F or an improper strand feed signal S is encountered at a service work station as shown at OR gate 103, the service tender is programmed for its sub-cycle of operation to cut the strand and doff the bobbin at 22. When this sequence is completed as indicated by a signal at lead 104, a new bobbin is mounted and connected to the strand for winding by unit 23.

In general a many spindled machine operated by a patrolling tender is set up to produce a substantially uniform pattern of attaining full bobbins so that each tender trip can doff all the full bobbins and make all the service stops necessary in the time allocated by the trip timer 102. However, if a condition were encountered where too many bobbins were serviced at one trip, say seven or more, then the requirement to make additional stops to service a no strand feed condition might result in failure to remove bobbins before an overfill condition where the bobbin rubs on the frame and becomes a useless black bobbin.

Thus, it is more important to doff full bobbins than to continue other servicing steps. For this reason a counter 105 is provided that is reset for each tender trip by the END pulse. When a count of service cycles, chosen as 7, for example, is attained on any trip this serves to inhibit the strand feed detector through gate 105' for the rest of the trip so that the tender returns to start another trip while ignoring strand feed detector 70. Also if a flag down signal D is encountered at any spindle position, the inhibit signal at gate 96 will cause the tender to continue patrolling without that station stop.

A counter 106 may be provided to show how many times the 7 mode is encountered, and will thus give information regarding efficiency of operation and possible need for maintenence or patch up of the machine in order to reachieve a substantially uniform code of filling bobbins.

Certain combinations of signals are used to indicate malfunctions. For example, the presence of strand feed signal (the absence of S) should not occur at a station with the presence of the flag down detector signal D. This indicates a malfunction, which can be stored as data, or used to provide an immediate malfunction indication.

A count of the bobbins doffed will give production information and give also an indication of operational efficiency. Thus counters 108 and 1119 are provided to register full and partial bobbins doffed respectively. Therefore, when the doffmg operation is complete as signified by the pulse at lead 104, a full bobbin is doffed if the F signal is present at AND gate 110 and conversely if an S signal is present at AND gate 111 it signifies a partial bobbin doffed if not inhibited by an F signal.

THE FLAG DOWN MODE The service tender 12 is equipped to disable any spindle station that cannot be serviced by placing the flag down at 24. One such condition is the presence of roll wrap, which condition is usually manually repaired. Thus at OR gate 112 the R signal serves to put the flag down for any station at which it is encountered. Also by a signal at lead 113 the flag is put down when the service tender cannot complete a successful service cycle as hereinafter explained.

THE REPEAT SERVICE CYCLE MODE As provided in the service cycle programmer sections 25 and 26, the program is set up for introducing a repeat service cycle by a pulse signal at lead 114. The logic of this embodiment provides for first and second service tries and records the number of each at respective counters 115, 116 for analysis of service performance and machine efficiency. A large number of second tries for example may indicate the need for maintenance of the spinning frame and thus a predetermined count at lead 117 may produce an alarm signal at indicator block 29. An excessive number of second tries, for example, could also be used in section 118 to stop the machine indicating the possibility of damage, or such a degree of inefficiency that it would be better to stop than continue.

The recycle mode is started at program time T in AND gate 1 19 after completion of a service cycle if the improper strand feed signal S still persists at OR gate 120. If a roll wrap R signal is encountered and a flag down signal D is not present, this condition (detected by AND gate 121) also shows the need for a repeated service cycle. Thus an NG pulse is provided at lead 122 when a repeat cycle is indicated.

The number of repeat service cycles must necessarily be limited and thus in this embodiment, counter 123 keeps track of the number of repeated cycles and is reset by a successful cycle provided by time pulse T at lead 124 through inhibit gate 125 if the NG signal is not present. Also the counter iscyclic. sothat itresets after a count of two automatically.

The first repeat service cycle tries 1 at lead serve to recycle the program at 26 when the programmer at 25 indicates the former service cycle is complete and the programmer 20 is in condition to be recycled. OR gate 126 also permits a second repeat service recycle on a second try count of 2 at lead 127.

The corresponding first repeat service cycle tries and second repeat service cycle tries may be recorded for each spindle position by counter banks 35 and 36 to provide information for maintenance by indicating misalignments, or other conditions that could cause certain spindles to require more repeat cycles than others. The total number of service cycles may be resistered on counter 128 and pulses on lead 124 could also record this data for each spindle by a further counter bank (not shown). A predetermined number of service tries could provide an alarm by way of block 129 should that be a desirable strategy for any particular machine location. Also any other predetermined counts taken from any of the counters throughout the system could be used to indicate either special or general alarms or control functions in block 29.

Flip-flop 130 is a control device to end the repeat service recycling program after the second service recycle try. It is set by the 2 count state at lead 127 to actuate AND gate 131 and provide at lead 113 a flag down signal to disable the spindle station and to register a count on 3 counter 132. The signal on lead 113 also provides through OR gate 133 a G0 signal starting the tender patrol toward the next service stop. This GO signal resets flip-flop 130.

The three counter is reset by an OK signal received from programmer section 25 through AND gate 125 when the next proper service cycle is completed. If three successive unsuccessful second tries 2 are encountered at lead 113, then a stop signal 3 is generated, since it indicates the probability that the machine is misaligned or damaged and that continued operation may be dangerous.

One other signal that may be used as an alarm is indicated at 1411 as bobbin feed signal B, encountered at OR gate 141 for example. If there are no bobbins supplied the don bobbin sub-program 23 cannot be successful so the signal may give a preliminary alarm at 29 or could stop the spinning frame at 28 if desired.

A comprehensive, useful data processing and machine control system is therefore afforded by this invention to permit more automated control of winding and textile machinery. Some of the comprehensive features included in the embodiment illustrated may be eliminated and further features may be included in order to achieve the objectives of providing operational history of various malfunctions for indicating machine operational efficiency, production records, and data for management planning, monitoring analysis and for deducing maintenance points and machine failures.

What is claimed is:

1. Automatic apparatus for monitoring and controlling a machine winding a plurality of bobbins with a strand at respective work stations comprising in combination, a servicing tender movable from one work station to another about said machine to service malfunctions at any of the stations, detection means carried by said tender to generate a plurality of current signals representative of the status of the work at the work stations, data processing means operable by said tender having a data recording section cumulatively recording said current signals, means performing a series of service steps responsive to a plurality of said current signals, and means for altering the machine operation performing at least one service step responsive to both said current correction signals and said cumulatively recorded signals.

2. Apparatus as defined in claim 1 wherein said data recording section comprises counting means producing said cumulatively recorded signals.

3. Apparatus as defined in claim 2 wherein said counting means is adapted to count the detected conditions per predetermined period of time.

4. Apparatus as defined in calim 2 wherein said counting means is adapted to count the detected conditions for each work station.

5. Apparatus as defined in calim 2 wherein said counting means is adapted to accumulate the count of detected conditions for all the work stations.

6. Apparatus as defined in claim 1 wherein the machine is a spinning frame and the strand is yarn.

7. Apparatus as defined in claim 1, wherein said tender comprises means for servicing said apparatus at selected ones of said work stations in response to said current signals and further comprising means selecting work stations for servicing by said tender thereby to correct selected malfunctions indicated by said data processing means in response to said cumulatively recorded signals.

8. Apparatus as defined in claim 1 wherein said detection means includes a detector providing a signal indicating the malfunction of a bobbin, and said means for alterig' the machine operation includes apparatus carried by said tender for doffing bobbins in response to said malfunction signal.

9. Apparatus as defined in claim 1 wherein said detection means includes a detector providing an improper bobbin feed signal indicating the lack of a bobbin at a work station, and said means for altering the machine operation responds thereto and includes apparatus carried by said tender for doffing a bobbin, donning a new bobbin and preparing it to wind said strand.

10. Apparatus as defined in claim 1 wherein the apparatus includes rolls for conveying said strand which can accumulate roll wrap of the strand as a malfunction, wherein said detection means includes a detector providing a signal indicating roll wrap, and said means for altering the machine operation includes apparatus carried by said tenderfor disabling and bypassing the stations at which roll wrap occurs.

11. Apparatus as defined in claim 1 wherein said detection means includes a detector providing a strand feed signal indicating the lack of proper feed of the strand to one of said bobbins at a work station, and said means for altering the machine operation includes apparatus carried by said tender responsive to the strand feed signal for doffing the bobbin, donning a new bobbin and connecting the strand to the new bobbin for winding.

12. Apparatus as defined in claim 1 wherein said detector means includes a detector providing a malfunction signal indicating an empty roving supply at a Sta-- tion.

13. Apparatus as defined in claim 1 wherein said tender comprises means for moving successively in a trip past all of said work stations throughout said plurality of bobbins, said detection means provides during transit of said tender in the vicinity of each station having a malfunction a signal indicating the need for a service operation at that station, and braking control means is provided responsive to said malfunction signal to stop said tender at those said stations indicating a malfunction to perform a service operation thereat.

14. Apparatus as defined in claim 13 wherein each bobbin is mounted on a spindle, including means for detecting and providing a spindle position pulse signal for the position of each spindle as the tender passes a work station and said braking control means responds to the spindle position pulse signal.

15. Apparatus as defined in claim 14 wherein said plurality of signals from said detection means on said tender to detect malfunctions comprise steady state malfunction signals persisting as long as the tender is at the work station, and respective gates to process each of said malfunction signals and provide a gated output signal in response to concurrence of the spindle position signal and the respective malfunction signal.

16. Apparatus as defined in claim 15 wherein said malfunction detection means includes at least two detectors providing signals indicating two of the following malfunctions: (a) full bobbin, (b) roll wrap, (c) inoperable station (flag down), (d) strand feed, (e) incomplete service cycle, (f) excessive cycle time, (g) excessive tender trip time, (h) excessive time between full bobbins, or (i) counting an excessive number of service operations per spindle, or per cycle or per unit time, and including servicing apparatus in said tender for correcting during a service cycle at the respective stations indicating a malfunction indicated by said detectors by the respective corresponding service operations of (a) doffing a full bobbin, donning and connecting a new bobbin, (b) making the station inoperable and putting a flag down, (c) bypassing the station without a service stop, (d) doffing the bobbin, donning a new bobbin and connecting thereto for winding the strand, (e) repeating the service cycle at that station and if still unsuccessful disabling the station (flag down) and continuing traverse of the tender, (f) stopping the winding machine, (g) stopping the tender and (h) displaying an alarm signal.

17. Apparatus as defined in claim 16 including counting means for displaying at least two of the following counts from signals sensed at each station as the tender traverses said trip: (a) the number of spindles passed, (b) the number of full bobbins detected, (c) the number of full bobbins doffed, (d) the number of improper strand feeds, (e) the number of service cycles completed, (f) the number of unsuccessful service cycles, (g) the number of partial bobbins doffed, (h) the number of roll wraps encountered, (i) the number of operable spindles.

18. Apparatus as defined in claim 17 including in said counting means apparatus for determining an accumulative count per predetermined period of time.

19. Apparatus as defined in claim 17 including in said counting means apparatus for determining an accumulative count for each spindle.

20. Apparatus as defined in claim 17 including in said counting means apparatus for determining an accumulative count for all spindles.

21. Apparatus as defined in claim 17 including means for operating an alarm in response to predetermined counts.

22. Apparatus as defined in claim 17 including means for operating an alarm in response to predetermined combinations of two or more counts.

23. Apparatus as defined in claim 1 wherein said malfunction detection means includes at least two detectors providing signals indicating two of the following malfunctions: (a) full bobbin, (b) roll wrap, (c) inoperable station (flag down), ((1) strand feed, (e) incomplete service cycle, (f) excessive cycle time, (g) excessive tender trip time, or (h) counting an excessive number of service operations per spindle, per cycle or per unit time, and including servicing apparatus in said tender for correcting during a service cycle at any of the respective stations indicating a malfunction by means of said detectors by means of the respective cor responding service operations of (a) doffing a full bobbin, (b) disabling a station and putting the flag down, (c) bypassing the station without a service stop, (cl) doffing the bobbin and reconnecting a new bobbin for winding the strand, (e) repeating the service cycle at that station and if still unsuccessful disabling the station (flag down) and continuing traverse of the tender, (f) stopping the winding machine, (g) stopping the tender and (h) operating an alarm.

24. Apparatus as defined in claim 23 including counting means for displaying at least two of the following counts from signals sensed at each station as the tender traverses said trip: (a) the number of spindles passed, (b) the number of full bobbins detected, (c) the number of full bobbins doffed, (d) the number of improper strand feeds, (e) the number of service cycles completed, (f) the number of unsuccessful service cycles, (g) the number of partial bobbins doffed, (h) the number of roll wraps encountered, (i) the number of operable spindles.

- 25. Apparatus as defined in claim 24 including in said counting means apparatus for determining an accumulative count per predetermined period of time.

26. Apparatus as defined in claim 24 including in said counting means apparatus for determining an accumulative count for each spindle.

27. Apparatus as defined in claim 24 including in said counting means apparatus for determining an accumulative count for all spindles.

28. Apparatus as defined in claim 24 including means for operating an alarm in response to predetermined counts.

29. Apparatus as defined in claim 24 including means for operating an alarm in response to predetermined combinations of at least two counts.

30. Apparatus as defined in claim 1 wherein the data processing means is positioned on said tender to move therewith.

31. Automatic apparatus for monitoring and controlling a machine winding a plurality of bobbins with a strand at respective work stations comprising in combination, a tender movable from one work station to another, detection means carried by said tender to determine a plurality of conditions representative of the status of the work at the work stations providing corresponding signals, data processing means responsive to a plurality of said signals to detect malfunctions and produce a correction signal therefrom, and means for altering the machine operation in response to said correction signal, wherein said tender comprises means for servicing said apparatus at said work stations comprising said means for altering operation thereby to correct malfunctions indicated by said data processing means, and wherein the tender periodically makes a service cycle of all said stations and including means storing a count accumulation of the number of service stops made during each cycle, and means responsive to a predetermined said count accumulation of designated malfunctions to move said tender through the remainder of said service cycle ignoring selected service stops at malfunctioning work stations.

32. Automatic data processing equipment for machinery including means to wind a plurality of bobbins with a strand at a correspondingplurality of work stations comprising in combination, sensing means movable from station to station indicating each of a plurality of station malfunctions requiring the stations to be serviced and the bobbins to be removed from said stations, recording means establishing a cumulative record of the operation of the machine by accumulating an indication of the malfunctions sensed, servicing means stopping at said stations for correcting malfunctions indicated by said sensing means, and means responsive to said cumulative record controlling operation of said servicing means at designated station stops.

33. Equipment as defined in claim 32 wherein the recording means comprises counters.

34. Equipment as defined in claim 33 wherein the counters include means for carrying a cumulative total of the bobbins malfunctions at all work stations as sensed by said sensing means.

35. Equipment as defined in claim 33 wherein the counters include means for indicating the bobbin malfunctions occurring at any one of the work stations.

36. Equipment as defined in claim 32 wherein one of said malfunctions comprises a strand misfeed, and the recording means additionally maintains a cumulative count of strand misfeed malfunctions.

37. Equipment as defined in claim 36 wherein the machinery includes automatic control means to service detected malfunctions by moving from station to station doffing bobbins and donning new bobbins, connection one of said bobbins to the strand for winding, including alarm means responsive to said cumulative count to stop the machinery from winding when a pre determined number of malfunctions is recorded.

38. Equipment as defined in claim 37 including means of sensing an unsuccessful service operation by said service means, and means recycling the serviceoperation in response thereto.

39. Equipment as defined in claim 37 including further recording means, and sensors providing data for recording therein from. operations of said service means.

40. Equipment as defined in claim 37 wherein the machinery is textile machinery comprising a spinning frame passing yarn over a roller, and the strand misfeed malfunction sensed by said sensing means is a roll wrap. l 

1. Automatic apparatus for monitoring and controlling a machine winding a plurality of bobbins with a strand at respective work stations comprising in combination, a servicing tender movable from one work station to another about said machine to service malfunctions at any of the stations, detection means carried by said tender to generate a plurality of current signals representative of the status of the work at the work stations, data processing means operable by said tender having a data recording section cumulatively recording said current signals, means performing a series of service steps responsive to a plurality of said current signalS, and means for altering the machine operation performing at least one service step responsive to both said current correction signals and said cumulatively recorded signals.
 2. Apparatus as defined in claim 1 wherein said data recording section comprises counting means producing said cumulatively recorded signals.
 3. Apparatus as defined in claim 2 wherein said counting means is adapted to count the detected conditions per predetermined period of time.
 4. Apparatus as defined in calim 2 wherein said counting means is adapted to count the detected conditions for each work station.
 5. Apparatus as defined in calim 2 wherein said counting means is adapted to accumulate the count of detected conditions for all the work stations.
 6. Apparatus as defined in claim 1 wherein the machine is a spinning frame and the strand is yarn.
 7. Apparatus as defined in claim 1, wherein said tender comprises means for servicing said apparatus at selected ones of said work stations in response to said current signals and further comprising means selecting work stations for servicing by said tender thereby to correct selected malfunctions indicated by said data processing means in response to said cumulatively recorded signals.
 8. Apparatus as defined in claim 1 wherein said detection means includes a detector providing a signal indicating the malfunction of a bobbin, and said means for alterig the machine operation includes apparatus carried by said tender for doffing bobbins in response to said malfunction signal.
 9. Apparatus as defined in claim 1 wherein said detection means includes a detector providing an improper bobbin feed signal indicating the lack of a bobbin at a work station, and said means for altering the machine operation responds thereto and includes apparatus carried by said tender for doffing a bobbin, donning a new bobbin and preparing it to wind said strand.
 10. Apparatus as defined in claim 1 wherein the apparatus includes rolls for conveying said strand which can accumulate roll wrap of the strand as a malfunction, wherein said detection means includes a detector providing a signal indicating roll wrap, and said means for altering the machine operation includes apparatus carried by said tender for disabling and bypassing the stations at which roll wrap occurs.
 11. Apparatus as defined in claim 1 wherein said detection means includes a detector providing a strand feed signal indicating the lack of proper feed of the strand to one of said bobbins at a work station, and said means for altering the machine operation includes apparatus carried by said tender responsive to the strand feed signal for doffing the bobbin, donning a new bobbin and connecting the strand to the new bobbin for winding.
 12. Apparatus as defined in claim 1 wherein said detector means includes a detector providing a malfunction signal indicating an empty roving supply at a station.
 13. Apparatus as defined in claim 1 wherein said tender comprises means for moving successively in a trip past all of said work stations throughout said plurality of bobbins, said detection means provides during transit of said tender in the vicinity of each station having a malfunction a signal indicating the need for a service operation at that station, and braking control means is provided responsive to said malfunction signal to stop said tender at those said stations indicating a malfunction to perform a service operation thereat.
 14. Apparatus as defined in claim 13 wherein each bobbin is mounted on a spindle, including means for detecting and providing a spindle position pulse signal for the position of each spindle as the tender passes a work station and said braking control means responds to the spindle position pulse signal.
 15. Apparatus as defined in claim 14 wherein said plurality of signals from said detection means on said tender to detect malfunctions comprise steady state malfunction signals persisting as long as the tender is at the work station, and respective gAtes to process each of said malfunction signals and provide a gated output signal in response to concurrence of the spindle position signal and the respective malfunction signal.
 16. Apparatus as defined in claim 15 wherein said malfunction detection means includes at least two detectors providing signals indicating two of the following malfunctions: (a) full bobbin, (b) roll wrap, (c) inoperable station (flag down), (d) strand feed, (e) incomplete service cycle, (f) excessive cycle time, (g) excessive tender trip time, (h) excessive time between full bobbins, or (i) counting an excessive number of service operations per spindle, or per cycle or per unit time, and including servicing apparatus in said tender for correcting during a service cycle at the respective stations indicating a malfunction indicated by said detectors by the respective corresponding service operations of (a) doffing a full bobbin, donning and connecting a new bobbin, (b) making the station inoperable and putting a flag down, (c) bypassing the station without a service stop, (d) doffing the bobbin, donning a new bobbin and connecting thereto for winding the strand, (e) repeating the service cycle at that station and if still unsuccessful disabling the station (flag down) and continuing traverse of the tender, (f) stopping the winding machine, (g) stopping the tender and (h) displaying an alarm signal.
 17. Apparatus as defined in claim 16 including counting means for displaying at least two of the following counts from signals sensed at each station as the tender traverses said trip: (a) the number of spindles passed, (b) the number of full bobbins detected, (c) the number of full bobbins doffed, (d) the number of improper strand feeds, (e) the number of service cycles completed, (f) the number of unsuccessful service cycles, (g) the number of partial bobbins doffed, (h) the number of roll wraps encountered, (i) the number of operable spindles.
 18. Apparatus as defined in claim 17 including in said counting means apparatus for determining an accumulative count per predetermined period of time.
 19. Apparatus as defined in claim 17 including in said counting means apparatus for determining an accumulative count for each spindle.
 20. Apparatus as defined in claim 17 including in said counting means apparatus for determining an accumulative count for all spindles.
 21. Apparatus as defined in claim 17 including means for operating an alarm in response to predetermined counts.
 22. Apparatus as defined in claim 17 including means for operating an alarm in response to predetermined combinations of two or more counts.
 23. Apparatus as defined in claim 1 wherein said malfunction detection means includes at least two detectors providing signals indicating two of the following malfunctions: (a) full bobbin, (b) roll wrap, (c) inoperable station (flag down), (d) strand feed, (e) incomplete service cycle, (f) excessive cycle time, (g) excessive tender trip time, or (h) counting an excessive number of service operations per spindle, per cycle or per unit time, and including servicing apparatus in said tender for correcting during a service cycle at any of the respective stations indicating a malfunction by means of said detectors by means of the respective corresponding service operations of (a) doffing a full bobbin, (b) disabling a station and putting the flag down, (c) bypassing the station without a service stop, (d) doffing the bobbin and reconnecting a new bobbin for winding the strand, (e) repeating the service cycle at that station and if still unsuccessful disabling the station (flag down) and continuing traverse of the tender, (f) stopping the winding machine, (g) stopping the tender and (h) operating an alarm.
 24. Apparatus as defined in claim 23 including counting means for displaying at least two of the following counts from signals sensed at each station as the tender traverses said trip: (a) the number of spindles passed, (b) the number of full bobbins detected, (c) the number of full bobbins doffed, (d) the number of improper strand feeds, (e) the number of service cycles completed, (f) the number of unsuccessful service cycles, (g) the number of partial bobbins doffed, (h) the number of roll wraps encountered, (i) the number of operable spindles.
 25. Apparatus as defined in claim 24 including in said counting means apparatus for determining an accumulative count per predetermined period of time.
 26. Apparatus as defined in claim 24 including in said counting means apparatus for determining an accumulative count for each spindle.
 27. Apparatus as defined in claim 24 including in said counting means apparatus for determining an accumulative count for all spindles.
 28. Apparatus as defined in claim 24 including means for operating an alarm in response to predetermined counts.
 29. Apparatus as defined in claim 24 including means for operating an alarm in response to predetermined combinations of at least two counts.
 30. Apparatus as defined in claim 1 wherein the data processing means is positioned on said tender to move therewith.
 31. Automatic apparatus for monitoring and controlling a machine winding a plurality of bobbins with a strand at respective work stations comprising in combination, a tender movable from one work station to another, detection means carried by said tender to determine a plurality of conditions representative of the status of the work at the work stations providing corresponding signals, data processing means responsive to a plurality of said signals to detect malfunctions and produce a correction signal therefrom, and means for altering the machine operation in response to said correction signal, wherein said tender comprises means for servicing said apparatus at said work stations comprising said means for altering operation thereby to correct malfunctions indicated by said data processing means, and wherein the tender periodically makes a service cycle of all said stations and including means storing a count accumulation of the number of service stops made during each cycle, and means responsive to a predetermined said count accumulation of designated malfunctions to move said tender through the remainder of said service cycle ignoring selected service stops at malfunctioning work stations.
 32. Automatic data processing equipment for machinery including means to wind a plurality of bobbins with a strand at a corresponding plurality of work stations comprising in combination, sensing means movable from station to station indicating each of a plurality of station malfunctions requiring the stations to be serviced and the bobbins to be removed from said stations, recording means establishing a cumulative record of the operation of the machine by accumulating an indication of the malfunctions sensed, servicing means stopping at said stations for correcting malfunctions indicated by said sensing means, and means responsive to said cumulative record controlling operation of said servicing means at designated station stops.
 33. Equipment as defined in claim 32 wherein the recording means comprises counters.
 34. Equipment as defined in claim 33 wherein the counters include means for carrying a cumulative total of the bobbins malfunctions at all work stations as sensed by said sensing means.
 35. Equipment as defined in claim 33 wherein the counters include means for indicating the bobbin malfunctions occurring at any one of the work stations.
 36. Equipment as defined in claim 32 wherein one of said malfunctions comprises a strand misfeed, and the recording means additionally maintains a cumulative count of strand misfeed malfunctions.
 37. Equipment as defined in claim 36 wherein the machinery includes automatic control means to service detected malfunctions by moving from station to station doffing bobbins and donning new bobbins, connection one of said bobbins to the strand for winding, including alarm means responsive to said cumulative count to stop the machinery from winding when a predetermined number of malfunctions is recorded.
 38. Equipment as defined in claim 37 including means of sensing an unsuccessful service operation by said service means, and means recycling the service operation in response thereto.
 39. Equipment as defined in claim 37 including further recording means, and sensors providing data for recording therein from operations of said service means.
 40. Equipment as defined in claim 37 wherein the machinery is textile machinery comprising a spinning frame passing yarn over a roller, and the strand misfeed malfunction sensed by said sensing means is a roll wrap. 